JP2011217511A - Stator for rotary electric machine and method for manufacturing the stator for the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a stator for a rotary electric machine, capable of preventing damage due to heat of spark in welding from being imposed to a stator winding on the lower part of a welded part when coil ends of conductors of annular inner and outer circumferences are welded.SOLUTION: The stator 50 for the rotary electric machine includes an annular stator core 30 having a plurality of slots 31 in a circumferential direction, and a stator winding 40 consisting of a plurality of conductors wound around the stator core 30. U, V and W winding wires forming the stator winding 40 each have at least two conductors, wherein an inner circumferential coil end 40a of one conductor and an outer circumferential coil end 40b of the other conductor are bent so as to oppose each other over the stator winding 40, and both bent edges are brought into contact and becomes a bonding part 51 by welding. Insulating members 53 each made of an annular insulated paper or insulating resin are interposed between the stator winding 40 and the bonding part 51 while covering the stator winding 40, and the bonding part 51 is welded.

Description

  The present invention relates to a stator for a rotating electrical machine such as an electric motor or a generator mounted on a vehicle such as an electric vehicle or a hybrid vehicle, and a method for manufacturing the stator for the rotating electrical machine.

  2. Description of the Related Art Conventionally, a stator for a rotating electrical machine is generally provided with an annular stator core having a plurality of slots in the circumferential direction and a stator winding composed of a plurality of conductive wires wound around the stator core. Known to. For example, in Patent Document 1, in order to improve the space factor of the conductors arranged in the slots (the proportion of the conductors in the slots), the cross-sectional shape in the direction perpendicular to the axis of the conductors is rectangular. In addition, a technique is disclosed in which a stator winding is constituted by each phase winding (U-phase conductor, V-phase conductor, W-phase conductor) whose overall shape when a conducting wire is expanded is meandering in a crank shape. In this case, each phase winding constituting the stator winding has a structure formed in a cylindrical shape by being wound around the stator core a predetermined number of times.

JP 2001-145286 A

  In the case of such a stator of a rotating electric machine, each phase winding constituting the stator winding has a structure formed in a cylindrical shape by winding it around the stator core a predetermined number of times. Therefore, each lead wire needs to be long.

  For this reason, the present applicant has applied for the stator 20 of the rotating electrical machine having the structure shown in FIG. 1 in Japanese Patent Application No. 2009-241798. The stator 20 includes an annular stator core 30 having a plurality of slots 31 in the circumferential direction shown in FIG. 2, and a stator winding 40 composed of a plurality of conductors wound around the stator core 30. Configured. In the stator winding 40, the first slot accommodating portion of the first to nth slot accommodating portions is disposed on the outermost diameter side of the slot 31, and the nth slot accommodating portion is disposed on the innermost diameter side of the slot 31. Each of the phase windings forming the stator winding has at least two conductors, and is connected to the first slot accommodating portion of one of the conductors and the nth of the other conductor. An inner peripheral end connected to the slot accommodating portion is connected by a crossover portion 70. More specifically, the crossover portion 70 includes a portion where the coil ends of both predetermined inner and outer conductors are in contact with each other and welded to each other, and a portion that crosses the annular shape of the stator core 30 in the radial direction. It is. Thus, each phase winding which comprises stator winding 40 is formed by connecting a plurality of conducting wires, and the length of one conducting wire is shortened.

  By the way, in the configuration of Japanese Patent Application No. 2009-241798, the conducting wire that becomes the transition portion 70 is divided in advance, and both the conducting wires are inserted into the slot 31 of the stator core 30 and then the coil ends of both conducting wires are welded together. A structure in which the connecting portions 70 are formed by joining is also conceivable. However, in the case of this structure, when the welded portion forming the crossover portion 70 is above the stator winding 40, sparks fly during welding such as arc welding, and the lower stator winding 40 is damaged by heat. There is a problem.

  The present invention has been made in view of such circumstances, and even if the coil ends of the conductors on the inner circumference side and the outer circumference side of the annular shape are welded to each other, the stator winding below the welded portion is used. An object of the present invention is to provide a stator for a rotating electrical machine and a method for manufacturing the stator for a rotating electrical machine that can prevent damage caused by heat such as sparks during welding.

  The invention according to claim 1, which has been made to achieve the above object, comprises an annular stator core having a plurality of slots in the circumferential direction, and a plurality of conductors wound around the stator core. An inner coil end portion of one conductive wire that forms the stator winding and an outer peripheral coil end portion of the other conductive wire are opposed to each other in an annular shape above the stator winding. In the stator of a rotating electrical machine that is bent in the radial direction of and is joined by welding with both bent end faces abutting between the stator winding and the joint where the both end faces are joined. Further, an annular insulating member along the shape of the stator core is interposed so as to cover the stator winding.

  According to this configuration, since the spark generated during welding of the joint portion falls on the insulating member, it does not fall on the stator winding below the insulating member. Therefore, the stator windings can be prevented from being damaged by heat such as sparks during welding.

  The invention according to claim 2 is characterized in that the insulating member is divided into a plurality of parts.

  According to this configuration, since each of the divided insulating members is small, after joining the joint portions arranged at predetermined intervals in the annular circumferential direction, the insulating member is removed from the gap between the circumferential joint portions. It becomes easy to do.

  The invention described in claim 3 includes an annular stator core having a plurality of slots in the circumferential direction, and a stator winding composed of a plurality of conductors wound around the stator core, and the fixed The inner coil end portion of one of the conductive wires forming the child winding and the outer coil end portion of the other conductive wire are bent in an annular radial direction above the stator winding so as to face each other. In a method of manufacturing a stator of a rotating electrical machine in which both bent end surfaces are brought into contact with each other, before the inner peripheral coil end portion and the outer peripheral coil end portion are bent, the stator winding is disposed above the stator winding. A first step of disposing an annular insulating member along the shape of the stator core in a state of covering the stator winding; and after disposing the insulating member in the first step, the inner peripheral coil The end and the outer coil end A second step of the end face of the rectangular is bent state in contact, characterized in that it comprises a third step of joining by welding the end surfaces of both of said abutting at the second step.

  According to this method, since the spark generated during welding of the joint falls on the insulating member, it does not fall on the stator winding below the insulating member. Therefore, the stator windings can be prevented from being damaged by heat such as sparks during welding.

  The invention described in claim 4 includes a fourth step of removing the insulating member after welding in the third step.

  According to this method, a stator having a normal configuration without an insulating member can be obtained.

  The invention according to claim 5 is characterized in that the insulating member is divided into a plurality of parts.

  According to this method, since each of the divided insulating members is small, after joining the joints arranged at predetermined intervals in the annular circumferential direction, the insulating members are removed from the gaps between the circumferential joints. It becomes easy to do.

It is a perspective view which shows the structure of the stator of the conventional rotary electric machine. It is a top view which shows the structure of the stator core of the stator of a rotary electric machine. It is a perspective view showing a schematic structure of a stator of a rotating electrical machine according to an embodiment of the present invention. It is a perspective view which shows the characteristic part of the stator of the rotary electric machine which concerns on this embodiment. It is a top view which shows the structure of an insulating member. It is a 1st figure for demonstrating the manufacturing method of the stator of the rotary electric machine which concerns on this embodiment. It is a 2nd figure for demonstrating the manufacturing method of the stator of the rotary electric machine which concerns on this embodiment. It is a top view which shows the other structure of an insulating member.

  Embodiments of the present invention will be described below with reference to the drawings. However, parts corresponding to each other in all the drawings in this specification are denoted by the same reference numerals, and description of the overlapping parts will be omitted as appropriate.

  FIG. 3 is a perspective view showing a schematic configuration of the stator of the rotating electrical machine according to the embodiment of the present invention.

  A stator 50 of the rotating electrical machine shown in FIG. 3 is a stator composed of an annular stator core 30 having a plurality of slots 31 (see FIG. 2) in the circumferential direction and a plurality of conductors wound around the stator core 30. And a child winding 40. Each of the UVW phase windings forming the stator winding 40 has at least two conductive wires, an inner peripheral coil end portion 40a disposed on the inner peripheral side of one of the conductive wires, and an outer peripheral side of the other conductive wire. The outer end coil end portion 40b disposed on the outer side is bent above the stator winding 40 so as to face each other, and both the bent end faces come into contact with each other and are joined (joined portion) 51 by welding. . The bent portion of the joint 51 is a crossing portion 52 that crosses the annular shape in the radial direction above the stator winding 40. However, the upper side of the stator winding 40 refers to the direction of the rotor rotation shaft (in the axial direction end side) disposed in the stator core 30.

  The feature of this embodiment is that, as shown in a partial detail view of FIG. 4, between the stator winding 40 and the joint portion 51 of the crossover portion 52, an annular insulating paper, insulating resin, or the like shown in FIG. 5. After the insulating member 53 is interposed, the joint 51 is welded. However, the annular shape of the insulating member 53 has a shape along the stator core 30.

  A procedure for performing welding with the insulating member 53 interposed will be described with reference to FIGS. However, FIG.6 and FIG.7 is a schematic sectional drawing at the time of seeing through the end surface part which cut | disconnected the annular | circular shaped stator 50 arrange | positioned horizontally at radial direction.

  As shown in FIG. 6A, the stator winding 40 and the inner and outer coil end portions 40a and 40b of the stator winding 40 are connected to the stator from above the stator core 30. Insert into the slot of the core 30 (see FIG. 2). This insertion is further advanced to protrude the stator winding 40, the inner peripheral coil end portion 40a, and the outer peripheral coil end portion 40b from below the stator core 30 as shown in FIG. 6B. Next, as shown in FIG. 6C, predetermined ones of the protruding stator winding 40, inner peripheral coil end portion 40a, and outer peripheral coil end portion 40b are joined together.

  Next, as shown in FIG. 7 (d), the insulating member 53 is disposed above the stator winding 40 protruding above the stator core 30 so as to cover all of the stator winding 40. After this arrangement, as shown in FIG. 7 (e), the inner peripheral coil end portion 40a and the outer peripheral coil end portion 40b protruding above the stator core 30 are bent in the horizontal direction, and both the bent portions are bent. Contact the end face. This abutting portion becomes the joint portion 51.

  Next, as shown by arrow Y1 in FIG. 7 (f), the joint 51 is welded by welding means such as arc welding. Sparks fly and fall during the welding, but the sparks fall on the insulating member 53. After the joining part 51 is joined by this welding to form the transition part 52, the insulating member 53 is removed as shown in FIG.

  Thus, according to the stator 50 of the rotating electrical machine of the present embodiment, the insulating member 53 is interposed between the stator winding 40 and the joint portion 51 of the transition portion 52 so as to cover the entire stator winding 40. After that, the joint 51 was welded. As a result, sparks generated during welding of the joint 51 fall on the insulating member 53, so that they do not fall on the stator winding 40 below the insulating member 53. Therefore, it is possible to prevent the stator winding 40 from being damaged by heat such as sparks during welding.

  Further, as shown in FIG. 8, the insulating member 53 may be divided into a plurality of parts as indicated by reference numerals 53-1 to 53-8. In this case, since each of the divided insulating members 53-1 to 53-8 is small, the insulating member 53 is inserted between the connecting portions 52 arranged at predetermined intervals in the circumferential direction after the joining portions 51 shown in FIG. 4 are joined. The merit which becomes easy to remove is obtained.

  Furthermore, the structure of the stator 50 with the insulating member 53 left, that is, by leaving the insulating member 53 having a smooth surface on both coil end portions 40a and 40b, the oil for cooling both coil ends flows in a laminar flow. As a result, it is possible to obtain an effect such that the cooling capacity is uniform over the entire coil end.

20, 50 Stator of rotating electrical machine 30 Stator core 31 Slot 40 Stator winding 40a Inner peripheral side coil end part 40b Outer peripheral side coil end part 51 Joint part 52, 70 Crossing part 53 Insulating member

Claims (5)

One conductor having an annular stator core having a plurality of slots in the circumferential direction, and a stator winding composed of a plurality of conductors wound around the stator core, and forming the stator winding The inner coil end portion of the other conductor and the outer coil end portion of the other conductor are bent in an annular radial direction above the stator winding, and both the bent end surfaces are in contact with each other. In the stator of a rotating electrical machine joined by welding,
An annular insulating member along the shape of the stator core is interposed between the stator winding and the joint where the both end faces are joined in a state of covering the stator winding. A stator of a rotating electric machine characterized by   The stator for a rotating electric machine according to claim 1, wherein the insulating member is divided into a plurality of parts. One conductor having an annular stator core having a plurality of slots in the circumferential direction, and a stator winding composed of a plurality of conductors wound around the stator core, and forming the stator winding The inner coil end portion of the other conductor and the outer coil end portion of the other lead wire are bent in an annular radial direction above the stator winding so as to face each other, and both the bent end faces are brought into contact with each other. In the manufacturing method of the stator of the rotating electrical machine to be joined,
An annular shape along the shape of the stator core in a state of covering the stator winding above the stator winding before bending the inner peripheral coil end portion and the outer peripheral coil end portion. A first step of disposing the insulating member;
A second step of bending the inner peripheral coil end portion and the outer peripheral coil end portion into a state where both end surfaces abut after the arrangement of the insulating member in the first step;
And a third step of joining the two end surfaces in contact with each other by welding in the second step.   The method for manufacturing a stator of a rotating electric machine according to claim 3, further comprising a fourth step of removing the insulating member after welding in the third step.   The method for manufacturing a stator of a rotating electrical machine according to claim 3 or 4, wherein the insulating member is divided into a plurality of parts.

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